Battery charger

ABSTRACT

A battery charger may include a printed circuit board (PCB) having a first portion supporting alternating current (AC) electrical components and a second portion supporting direct current (DC) electrical components; an indicator including a light-emitting diode (LED) supported on the first portion of the PCB and operable to emit light; and an isolating member positioned on the first portion between the AC electrical components and the LED. A trace on the PCB may be electrically connected to the second portion of the PCB, the trace extending from the second portion and along the first portion, and the LED may be electrically connected to and receiving DC power through the trace, the LED being selectively positioned along a length of the trace. The LED may be positioned more than about 8 mm from the AC electrical components.

TECHNICAL FIELD

The present utility model relates to battery chargers and, moreparticularly, to cooling a battery charger.

BACKGROUND

A typical battery charger includes a battery charging circuit which isconnectable to a power source and to a rechargeable battery and which isoperable to charge the battery.

SUMMARY

In one independent embodiment, a battery charger may generally include ahousing defining an air inlet and an air outlet; charger electronicspositioned within the housing; a tubular heat sink operable to dissipateheat in the charger; a fan operable to cause air flow from the inlet tothe outlet and along the heat sink; and a diverter integral with andextending within the housing, the diverter being configured tofacilitate the air flow from the air inlet to the air outlet.

The diverter may be configured to create turbulent air flow within thehousing. In some constructions, the diverter extends from a top of thehousing. The housing may include a diverter extending from a bottom ofthe housing, the diverter being configured to direct air along a bottomof and/or through the charger electronics. The fan may be between an endof the heat sink and the air outlet. A baffle may be connected betweenthe end of the heat sink and the fan.

In another independent embodiment, a battery charger may generallyinclude a housing defining an air inlet positioned on a first side ofthe housing and an air outlet positioned on an opposite second side ofthe housing; charger electronics positioned within the housing; atubular heat sink operable to dissipate heat in the charger; and a fanoperable to cause air flow from the inlet to the outlet and along theheat sink.

In some constructions, the first side may be a front of the housing, andthe second side may be a back of the housing such that the second sidemay be opposite the first side. The first side may be a front of thehousing, and the second side may be adjacent and oriented about 90degrees relative to the first side. The air inlet may be positionedproximate a battery couplable to the charger; however, air flow may notenter or exit the battery before or after flowing through the housing ofthe charger.

The battery charger may further include a second air inlet positioned ona third side of the housing. The third air inlet may be configured todirect air flow along a bottom of the charger electronics. The chargerelectronics may include a second heat sink for dissipating heat fromcomponents of the charger electronics to the bottom of the chargerelectronics. The tubular heat sink may include a slot for directing theair flow from the heat sink over a component of the charger electronics.

In yet another independent embodiment, a battery charger may generallyinclude a housing having support structure for supporting at least twodifferent types of batteries for charging; charger electronics operableto output a charging current to charge a supported battery; and a fanoperable to cause air flow through the housing. A fan speed may beadjusted based on a temperature of the charger regardless if one of thebatteries is coupled to the charger.

In a further independent embodiment, a battery charger may generallyinclude a housing having support structure for supporting differenttypes of batteries for charging; charger electronics operable to outputa charging current to charge a supported battery; and an indictorpositioned on the housing and operable to indicate an operation of thecharger, the indicator including a light pipe for illuminating theindicator.

In another independent aspect, a battery charger may generally include ahousing including a support portion connectable to and operable tosupport a battery pack, the support portion defining a channel operableto receive a projection on the battery pack, the support portionincluding a plastic material molded to define the channel, and a metalmaterial molded in the plastic material, the metal material defining aC-shaped portion around the channel; a charging circuit supported by thehousing; and a charger terminal electrically connected to the chargingcircuit and connectable to a terminal of the battery pack.

In yet another independent aspect, a battery charger may generallyinclude a housing including a support portion operable to support abattery pack for charging; charging circuitry operable to supply currentto charge the battery pack; a printed circuit board (PCB) supported bythe housing, the PCB having a first portion supporting alternatingcurrent (AC) electrical components and a second portion supportingdirect current (DC) electrical components; an indicator supported on thehousing and associated with the support portion, the indicator includinga light-emitting diode (LED) supported on the first portion of the PCBand operable to emit light; and an isolator positioned between the LEDand the AC components (e.g., positioned on the PCB between the LED andthe AC components, extending through a slot in the PCB to be positionedbetween the LED and the AC components, etc.).

In another independent aspect, a battery charger may generally include ahousing including a support portion operable to support a battery forcharging; charging circuitry operable to supply current to charge thebattery; a PCB supported by the housing, the PCB having a first portionsupporting AC electrical components and a second portion supporting DCelectrical components; and an indicator supported on the housing andassociated with the support portion, the indicator including a LEDsupported on the first portion of the PCB and operable to emit light,the LED being positioned more than 8 mm from the AC electricalcomponents.

In a further independent aspect, a battery charger may generally includea housing including a support portion operable to support a battery packfor charging; charging circuitry operable to supply current to chargethe battery pack; a PCB supported by the housing, the PCB having a firstportion supporting AC components and a second portion supporting DCcomponents, a trace on the PCB being electrically connected to thesecond portion of the PCB, the trace extending from the second portionand along the first portion; and an indicator supported on the housingand associated with the support portion, the indicator including a LEDsupported on the first portion of the PCB and operable to emit light,the LED being electrically connected to and receiving DC power throughthe trace, the LED being selectively positioned along a length of thetrace.

Other independent aspects of the utility model will become apparent byconsideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a battery charger supporting differenttypes of batteries for charging.

FIG. 2 is a perspective view of an alternative construction of a batterycharger for charging different types of batteries.

FIG. 3 is a top view of the charger of FIG. 2.

FIG. 4 is a bottom perspective of the charger of FIG. 2.

FIG. 5 is a bottom perspective view of a portion of a housing of thecharger of FIG. 2.

FIG. 6 is a top perspective view of the charger of FIG. 2, with portionsof the housing removed and illustrating a circuit board.

FIG. 7 is another top perspective view of the charger of FIG. 2, withportions of the housing removed.

FIG. 8 is a flow chart illustrating a method of operating the charger ofFIG. 2.

FIG. 9 is a top perspective view of the charger of FIG. 2, with portionsof the housing shown as transparent and illustrating an airflow patternthrough the housing.

FIG. 10A is a cross-sectional view of a portion of the charger of FIG.2.

FIG. 10B is a top view of the portion of the charger shown in FIG. 10B.

FIG. 11A is a rear perspective view of a portion of a battery chargerincluding a circuit board.

FIG. 11B is a top view of the portion of the charger of FIG. 11A.

FIG. 12 is an enlarged top view of a portion of the charger of FIG. 11A.

FIG. 13 is an enlarged rear perspective view of the portion of thecharger of FIG. 11A, illustrating a light source.

FIG. 13A is an enlarged top view of a portion of the circuit board ofFIG. 13.

DETAILED DESCRIPTION

Before any independent embodiments of the utility model are explained indetail, it is to be understood that the utility model is not limited inits application to the details of construction and the arrangement ofcomponents set forth in the following description or illustrated in thefollowing drawings. The utility model is capable of other independentembodiments and of being practiced or of being carried out in variousways.

Use of “including” and “comprising” and variations thereof as usedherein is meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Use of “consisting of” andvariations thereof as used herein is meant to encompass only the itemslisted thereafter and equivalents thereof.

Relative terminology, such as, for example, “about”, “approximately”,“substantially”, etc., used in connection with a quantity or conditionwould be understood by those of ordinary skill to be inclusive of thestated value and has the meaning dictated by the context (for example,the term includes at least the degree of error associated with themeasurement of, tolerances (e.g., manufacturing, assembly, use, etc.)associated with the particular value, etc.). Such terminology shouldalso be considered as disclosing the range defined by the absolutevalues of the two endpoints. For example, the expression “from about 2to about 4” also discloses the range “from 2 to 4”. The relativeterminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%or more) of an indicated value.

Also, the functionality described herein as being performed by onecomponent may be performed by multiple components in a distributedmanner. Likewise, functionality performed by multiple components may beconsolidated and performed by a single component. Similarly, a componentdescribed as performing particular functionality may also performadditional functionality not described herein. For example, a device orstructure that is “configured” in a certain way is configured in atleast that way but may also be configured in ways that are not listed.

Furthermore, some embodiments described herein may include one or moreelectronic processors configured to perform the described functionalityby executing instructions stored in non-transitory, computer-readablemedium. Similarly, embodiments described herein may be implemented asnon-transitory, computer-readable medium storing instructions executableby one or more electronic processors to perform the describedfunctionality. As used in the present application, “non-transitorycomputer-readable medium” comprises all computer-readable media but doesnot consist of a transitory, propagating signal. Accordingly,non-transitory computer-readable medium may include, for example, a harddisk, a CD-ROM, an optical storage device, a magnetic storage device, aROM (Read Only Memory), a RAM (Random Access Memory), register memory, aprocessor cache, or any combination thereof.

Many of the modules and logical structures described are capable ofbeing implemented in software executed by a microprocessor or a similardevice or of being implemented in hardware using a variety of componentsincluding, for example, application specific integrated circuits(“ASICs”). Terms like “controller” and “module” may include or refer toboth hardware and/or software. Capitalized terms conform to commonpractices and help correlate the description with the coding examples,equations, and/or drawings. However, no specific meaning is implied orshould be inferred simply due to the use of capitalization. Thus, theclaims should not be limited to the specific examples or terminology orto any specific hardware or software implementation or combination ofsoftware or hardware.

FIG. 1 illustrates a battery charger 10 operable to charge a battery14A, 14B coupled to the charger 10. In the illustrated construction, thebattery charger 10 is operable to charge a first battery 14A of a firsttype and a second battery 14B of a second type. The illustrated batterycharger 10 may be operable to charge a high output battery (e.g., havinga current capacity of 12 amp-hours (Ah) or more), which requires about 3times the power of typical chargers, in about 60 minutes.

The battery type may be defined by nominal voltage, current capacity,connection configuration (e.g., “tower” vs. “slide-on”), etc., of thebattery 14A, 14B. For example, the first battery 14A may include ahigh-power battery pack with a nominal voltage of about 12 volts (V) andhaving a tower-style configuration, and the second battery 14A mayinclude a high-power battery pack with a nominal voltage of 18V and aslide-on configuration. In other constructions (not shown), thebatteries 14A, 14B may be the same type of battery.

Each battery 14A, 14B is connectable to and operable to power variousmotorized power tools (e.g., a cut-off saw, a miter saw, a table saw, acore drill, an auger, a breaker, a demolition hammer, a compactor, avibrator, a compressor, a drain cleaner, a welder, a cable tugger, apump, etc.), outdoor tools (e.g., a chain saw, a string trimmer, a hedgetrimmer, a blower, a lawn mower, etc.), other motorized devices (e.g.,vehicles, utility carts, a material handling cart, etc.), andnon-motorized electrical devices (e.g., a power supply, a light, anAC/DC adapter, a generator, etc.).

The charger 10 includes a housing 18 providing support structure 22A,22B (FIG. 2) engageable with the respective batteries 14A, 14B, a powerinput port 26 for connection to a power supply (e.g., through a powercord 30), charger electronics 34 (FIG. 6), and a heat dissipatingstructure 38. Air flow (e.g., green lines; FIG. 9) is configured to flowthough the housing 18 for dissipating heat generated by the charger 10.

With reference to FIG. 2, the charger housing 18 has a top portion 42Aand an opposite bottom portion 42B coupled to the top portion 42A (e.g.,by fasteners (not shown)). The housing portions 42A, 42B may be formedof plastic with each molded as a single piece.

The top portion 42A has a top wall 46, a lower wall 48, and an inclinedwall 50 coupled between the walls 46, 48. The top wall 46 is spaced fromthe bottom portion 42B, and the lower wall 48 is substantiallyperpendicular to the bottom portion 42B. The top wall 46 provides thetop of the housing 18, and the bottom portion 42B provides a bottom ofthe housing 18 opposite the top. The inclined wall 50 and the lower wall48 provide a front of the housing 18. The top portion 42A furtherincludes a back wall 54 opposite the front and opposite side walls 56,60. The bottom portion 42B has a raised wall 62 interfacing with one ormore walls (e.g., the back wall 54, the side walls 56, 60, etc.) of theportion 42A.

The housing 18 provides the battery support structure 22A, 22B. Eachsupport structure 22A, 22B is at least partially positionedsubstantially on the front of the housing (e.g., on the inclined wall50) and defines adjacent supporting sections 64A, 64B. The supportingsections 64A, 64B are configured to support the batteries 14A, 14B,respectively.

The illustrated supporting section 64A defines a recess 70, as a batteryreceiving port, defined by the top wall 46 and the inclined wall 50. Therecess 70 is configured to receive at least a portion (e.g., the tower)of the battery 14A. A first set of charger terminals 74 (FIG. 6) extendfrom within the housing 18 through holes into the recess 70. The chargerterminals 74 are configured to electrically connect to battery terminalsof the battery 14A received in the recess 70 for charging.

The illustrated supporting section 64B includes rail members 80A, 80Band a charger terminal block 84. The rail members 80A, 80B are spacedapart, substantially parallel and positioned on the inclined wall 50. Agroove 88A, 88B is defined between the inclined wall 50 and theassociated rail member 88A, 88B. The rail members 80A, 80B and grooves88A, 88B are engageable with corresponding structure on the battery 14B.The charger terminal block 84 is positioned between the rail members80A, 80B and includes a second set of charger terminals 92 configured toelectrically connect to battery terminals of the battery 14A forcharging.

In some embodiments (see FIGS. 10A-10B), the rail members 80A, 80Binclude a reinforcement member 82. The illustrated reinforcement member82 (e.g., green member) is molded as a part of the housing 18 with therail members 80A, 80B and with the supporting section 64B. Theillustrated reinforcement member 82 is formed as a single piece ofreinforcing material, such as metal (e.g., a metal stamping), hardplastic, etc. In other embodiments (not shown), the reinforcement member82 is formed by two or more pieces coupled together.

With reference to FIGS. 2-4, the housing 18 defines an air inlet 96 inthe inclined wall 50 and positioned below the first supporting section64A (e.g., the recess 70). As such, the illustrated air inlet 96 isbelow the battery 14A when coupled to the charger 10. In addition, theillustrated inlet 96 is positioned on the front of the housing 18 andincludes slots 100 (e.g., longitudinal slots) defined in the inclinedwall 50 and, partially, by the lower wall 48. The illustrated slots 100extend through the inclined wall 50 into the interior of the housing 18.The slots 100 extend from proximate the top wall 46 to the lower wall48. In other embodiments (not shown), the slots 100 may extend in alatitudinal direction, a combination longitudinal/latitudinal direction,etc. The slots 100 are configured to facilitate air flow into thehousing 18.

The housing 18 also defines an air outlet 104 positioned on the side 56of the housing 18 and proximate the back 54. The outlet 104 includesslots 108 (e.g., longitudinal slots) defined by the side 56 andextending from proximate the bottom portion 42B to proximate the topportion 42A (e.g., the top wall 46). In other embodiments (not shown),the slots 108 may extend in a latitudinal direction, a combinationlongitudinal/latitudinal direction, etc. The slots 108 are configured tofacilitate air flow exiting the housing 18. The inlet 96 and the outlet104 are positioned on different locations of the housing 18 (e.g., asillustrated, the outlet 104 is positioned on the side 56 oriented at 90degrees relative to the front of the housing 18).

The housing 18 may include more than one inlet and/or outlet. Forexample, as shown in FIG. 4, the housing 18 further defines a second airinlet 110 (FIG. 4) positioned on the bottom. The illustrated second airinlet 110 is defined by the bottom portion 42B. The second air inlet 110includes slots 114 proximate the front (e.g., the lower wall 48) and theside 56 of the housing 18. The second air inlet 110 may facilitate airflow to a bottom side 118 (FIG. 6) of the charger electronics 34, asfurther discussed below.

It should be understood that, in other constructions (not shown), thefirst inlet 96, the second inlet 110, and/or the outlet 104 may bepositioned on any side of the housing 18 (e.g., the back 54, the otherside 60, the bottom, etc.).

The slots 100, 108, 114 may have the same or different lengths. Forexample, the illustrated slots 100 of the first inlet 96 have differentlengths. The illustrated slots 114, 108 of each of the second inlet 110and the outlet 104, respectively, have the same length. Furthermore, theslots 100, 108, 114 may have any shape, such as, rectangular,triangular, trapezoidal, etc. For example, FIG. 3 illustrates the inlet96 formed by rectangular and trapezoidal slots, while FIG. 4 illustratesthe outlet 104 being formed by generally rectangular slots.

With reference to FIG. 4, feet members 120 extend from and areconfigured to position the bottom portion 42B of the housing 18 at adistance (e.g., three millimeters (3 mm)) from a work surface (e.g., atable). Furthermore, the feet members 120 are configured to facilitateair flow to the second inlet 110. The illustrated feet members 120include an elastomeric material and to improve support (e.g.,frictional, vibrational, etc.) of the charger 10 on the work surface.

With reference to FIGS. 2-3, the top portion 42A includes an indiciaregion 126 in which logos, images, brands, text, marks, etc., aredisplayed. The illustrated indicia region 126 is positioned on the topwall 46 and above the second supporting section 64B. The housing 18 mayinclude one or more indicia regions positioned on any of the sides(e.g., top, bottom, back 54, etc.). Furthermore, the top wall 46 mayinclude another indicia region above the first supporting section 64A.

The top portion 42A includes a plurality of openings 130 (e.g., twoopenings 130A, 130B) defined by the top wall 46 and positioned proximatethe back 54 of the housing 18. One opening 130A is positioned oppositethe first supporting section 64A, and the other opening 130B ispositioned opposite the second supporting section 64B. The openings130A, 130B may be configured to receive a lens 134 (only one of which isshown in FIG. 1). A light source (e.g., a light-emitting diode (LED))may be provided within the housing 18 to illuminate the lens 134. Assuch, the openings 130A, 130B and the lens 134 are configured to formindicators on the top portion 42A. Each supporting section 64A, 64B hasan indicator for indicating an operation (e.g., charging) of the charger10.

The illustrated power input port 26 is positioned on the front of thehousing 18, and below the second supporting section 64B (FIG. 2). Morespecifically, the power input port 26 is defined in the lower wall 48.In other embodiments (not shown), the power input port 26 may be locatedon any side (e.g., back 54, bottom, etc. of the housing 18). Theillustrated power cord 30 extends from the charger electronics 34 withinthe housing 18 (FIG. 6) through the power input port 26 to the powersource.

With reference to FIGS. 6-7, the charger electronics 34 are supported bythe bottom portion 42B. The charger electronics 34 are operable tooutput a charging current to one or both of the batteries 14A, 14B tocharge the batteries 14A, 14B. The charger electronics 34 include, amongother things, a printed circuit board (PCB) 140, a chargermicrocontroller (not shown), and a transformer 144. The chargerelectronics 34 may include a charging circuit portion (not shown; e.g.,on separate PCBs) for each of the batteries 14A, 14B so that eachbattery 14A, 14B may be charged simultaneously and independently. Thecharging current provided to each battery 14A, 14B may be the same ordifferent.

The charger 10 further includes a heat sink 150 and a fan 154 within thehousing 18 to provide the heat dissipating structure 38. A temperaturesensor (not shown) is disposed in the housing 18 and positioned near thecharger electronics 34 (e.g., near the component(s) generating the mostheat (e.g., the CPU, the transformer 144, field effect transistors(FETs), etc.)) or the heat sink 150. In the illustrated embodiment, thetemperature sensor is positioned proximate a side of the heat sink 150.

In the illustrated construction, the heat sink 150 is disposed in thehousing 18 proximate the back 54. In other constructions (not shown),the heat sink 150 may be positioned at other locations in the housing 18(e.g., proximate the front, the sides 56, 60, etc.). The heat sink 150is in heat transfer relationship with components of the chargerelectronics 34 (e.g., is mounted onto and in contact with the PCB 140).In other words, heat transfers from the heat-generating components ofthe charger 10 to the heat sink 150 through conduction.

In the illustrated embodiment, the heat sink 150 is formed ofheat-conducting material, such as, for example, aluminum, and extendsbetween opposite ends 158A, 158B. Furthermore, the illustrated heat sink150 is constructed of one or more hollow tubes 162 (three are shown inFIG. 7), each having a rectangular shape and stacked above one another.The tubes 162 extend between the opposite ends 158A, 158B. As such, theillustrated heat sink 150 forms a tubular heat sink.

In other constructions (not shown), the hollow tube(s) 162 may haveanother shape, such as, for example, triangular, cylindrical, etc., andthe heat sink 150 may have any number of tubes 162 (e.g., one, two, morethan three). The charger 10 may include more than one heat sink 150.

The first end 158A forms an inlet of each tube 162 for air flow to enterthe heat sink 150, and the second end 158B forms an outlet of each tube162 for air flow to exit the heat sink 150. As shown in FIG. 7, theinlet of each tube 162 is angled toward the front of the housing 18.

The illustrated fan 154 is positioned between the second end 158B of theheat sink 150 and the outlet 104. A baffle 166 extends between thesecond end 158B and the fan 154 for directing air flow from the heatsink 150 to the outlet 104. Projections 170A, 170B extend from the topportion 42A (FIG. 5) and the bottom portion 42B (FIG. 6). The fan 154 ispositioned between (i.e., sandwiched between) the projections 170A, 170Bto be secured within the housing 18.

The illustrated fan 154 is a multi-speed fan operable to rotate at morethan one speed and directs air flow from the inlet 96 through thehousing 18 and to the outlet 104. The speed at which the fan 154 rotatesmay be determined based on a temperature of one or more of the chargerelectronics 34, the heat sink 150, a supported battery 14A, 14B, etc.The temperature sensor (not shown) is configured to measure thetemperature and transmit a signal output to the microcontroller fordetermining the temperature of the charger 10. Subsequently, themicrocontroller controls the speed of the fan 154 based on thetemperature (e.g., of the heat sink 150, as illustrated). In someembodiments, at full speed, the fan 154 generates an air flow of betweenabout 13.6 m³/hour and about 25.5 m³/hour. Still further, in someembodiments, the fan 154 may generate an air flow of about 20.4 cubicfeet per minute (CFM) and up to about 35 m³/hour or less.

With reference to FIG. 5, the top portion 42A of the housing 18 includesa plurality of wall members 176 extending from an inner surface 180. Thewall members 176 are integral with the top portion 42A and areconfigured to form a fluid diverter within the housing 18. The divertermay direct air (FIG. 6) from the inlet 96 over the charger electronics34 (e.g., the PCB 140) to the heat sink 150. Furthermore, the diverteris configured to create turbulent fluid flow and may, therefore,increase air flow through the housing 18 and/or facilitate dissipationof heat from the housing 18. The bottom portion 42B may also includesimilar integral wall members or diverters for further directing airflow through the housing 18. The wall members 176 may further extendthrough the PCB 140 for directing air flow through the PCB 140 andthrough the housing 18.

As shown in FIG. 6, the charger 10 defines a flow path A through thehousing 18. In the illustrated embodiment, air flows along the flow pathA from the inlet 96, over the charger electronics 34 (e.g., the PCB 140)to the inlet of the heat sink 150, and through the heat sink 150 to theoutlet 104. The fan 154 directs air flow along the flow path A.Furthermore, the fan 154 directs air flow into the inlet and out of theoutlet of each tube 162. The air flow operates to dissipate heatgenerated by the charger electronics 34 from the housing 18. In otherembodiments (not shown), the fan 154 may be operated in reverse suchthat the flow path A through the housing 18 is reversed.

In one example (see FIG. 9 in which the housing 18 and the heat sink 150are shown as transparent to illustrate the air flow), air (e.g., greenlines) flows from the inlet 96 to the outlet 104 through the housing 18.Specifically, air flows from the inlet 96, over the charger electronics34, and through the heat sink 150 to the outlet 104. The inlet 96, theheat sink 150, and the outlet 104 are positioned to direct the air alongthis flow path for dissipating the heat generated by the charger 10.

The charger 10 may further define a second flow path in fluidcommunication with the second inlet 110. Specifically, air flows intothe bottom of the housing 18 through the second inlet 110 and pastcomponents of the charger electronics 34 positioned on the bottom side118 of the PCB 140. Air flow in the second flow path may be combinedwith air flow in the first flow path from the first inlet 96 to exit theoutlet 104. As such, air flow within the housing 18 may be separatedalong at least a portion of the flow paths through the housing 18.

The PCB 140 may further include a heat sink or copper (not shown)extending from a top side 184 through the PCB 140 to the bottom side 118to dissipate heat generated by any of the components of the chargerelectronics 34 to the bottom side 118. Air entering the housing 18through the second inlet 110 is configured to flow past the bottom side118 to further facilitate dissipation of heat of the charger electronics34 from the housing 18.

The heat sink 150 may include a slot (not shown) proximate one or someof the components of the charger electronics 34, such as, for example,the transformer 144. The slot may be configured to direct a portion ofair flowing through the heat sink 150 over a specific component (e.g.,the transformer 144) on the PCB 140. As such, air may flow at leastpartially through the heat sink 150 more than once.

With reference to FIGS. 6-7, the charger 10 includes a plurality oflight pipes 190 (e.g., two light pipes 190A, 190B), each extending to anopening 130A, 130B defined by the top portion 42A. Each light pipe 190A,190B directs light from an associated light source to each indicator. Inone embodiment, a number (e.g., two shown) of light emitting diodes(LEDs) are positioned on and electrically connected to the PCB 140. EachLED emits light, and the associated light pipe 190A, 190B is configuredto direct the light to the indicator on the top portion 42A of thehousing 18. The light pipes 190A, 190B are in heat transfer relationship((e.g., mounted onto and in contact) with the heat sink 150 fortransferring heat generated by the light pipes 190A, 190B to the heatsink 150.

The light pipes 190A, 190B (i.e., the respective LEDs) are electricallyconnected to the charger electronics 34 for controlling illumination ofthe light pipes 190A, 190B. For example, the indicator of the firstsupporting section 64A (i.e., the light pipe 190A) may be operated whenthe first battery 14A is electrically connected to the charger terminals74 of the first supporting section 64A. As such, the indicators may beconfigured to indicate to a user when the respective batteries 14A, 14Bare connected and charging.

In operation, one or both of the batteries 14A, 14B are coupled to therespective battery support structure 22A, 22B (e.g., the supportingsections 64A, 64B) for charging. The first set of terminals 74electrically connect with the battery terminals of the first battery14A, and/or the second set of terminals 92 electrically connect with thebattery terminals of the second battery 14B. The charger 10 suppliescharging current to the first and/or second battery 14A, 14B. Eachindicator indicates to the user the charging operation for theassociated battery 14A, 14B (e.g., completion of charging (i.e., whenthe charging current is zero Amps (0 A)).

As mentioned above, in the illustrated construction, the fan 154 is amulti-speed fan. With reference to FIG. 8, the microcontrollerdetermines the charger temperature (e.g., of the heat sink(s) 150, thecharger electronics 34, etc.) and, when the temperature reaches orexceeds a threshold, activates the fan 154 to operate at a correspondingfan speed. For example, if the microcontroller detects a temperature ofX ° C. (e.g., about 50% maximum operating temperature), then the fan 154is activated at X % speed (e.g., about 50% speed). It should beunderstood that, in other embodiments, the fan 154 may be activated at adifferent speed (e.g., more than 50% (100%, 75%, etc.) or less than 50%(25%, 10%, etc.)). Also, the speed of the fan 154 may be based on thesensed temperature (e.g., higher for a higher temperature or lower for alower temperature) and/or a duration the sensed temperature exceeds athreshold (e.g., higher for a longer duration or lower for a shorterduration).

If the fan 154 is not at the maximum speed, then the speed of the fan154 may be increased by X % (e.g., about an additional 10%), and theloop starts over (i.e., measuring the battery temperature and thecharger temperature). It should be understood that, in otherembodiments, the speed of the fan 154 may be increased by a differentamount (e.g., 5%, 15%, 25%, etc.)). Also, the increase in the speed ofthe fan 154 may be based on the sensed temperature and/or duration thesensed temperature exceeds a threshold.

If the fan 154 is at the maximum speed, the microcontroller maydetermine the charging current output of the charger 10. If the chargingcurrent output is not 0 A, then the charge current may be reduced by X %(e.g., about 10%), and the loop may start over (i.e. measuring thebattery temperature and the charger temperature). It should beunderstood that, in other embodiments, the charge current may be reducedby a different amount (e.g., 5%, 15%, 25%, 50%, etc.)). Also, thereduction in the charge current may be based on the sensed temperatureand/or duration the sensed temperature exceeds a threshold.

The microcontroller determines the charger temperature and controls thespeed of the fan 154 regardless whether either of the batteries 14A, 14Bis coupled to the charger 10. The microcontroller deactivates the fan154 only if the sensed temperature is below a threshold (e.g., a lowerlimit of the charger 10).

Thus, the utility model may provide, among other things, a charger 10operable to charge different types of batteries 14A, 14B at the sametime, and a method for dissipating heat regardless whether the batteries14A, 14B are coupled to the charger 10. The charger 10 may includestructure (e.g., a diverter) integral with and positioned within thehousing 18 and operable to direct air flow from the inlet 96 through thehousing 18 to the outlet 104. The inlet 96 and the outlet 104 may bedefined by adjacent sides (e.g., the front and the side 56) or onopposite sides (e.g., the front and the back).

FIGS. 11A-11B illustrate a charger 10 and charger electronics 34including a printed circuit board (PCB) 140′ positionable within thehousing 18. A plurality of portions 200A, 200B form the PCB 140, 140′.Similar to the PCB 140, the PCB 140′ includes a transformer 144′,positioned between the portions 200A, 200B. The PCB 140′ is configuredto facilitate charging of the one or more batteries 14A, 14B.

Alternating current (AC) electrical components 202A, operable to receiveAC power from a power source (e.g., line power through the cord 30), aresupported on the first portion 200A, and direct current (DC) electricalcomponents 202B, operable to output DC power to charge the batterypack(s) 14A, 14B, are supported on the second portion 200B. The ACelectrical components include (see FIG. 11B), among other things,capacitors 204A, a resistor 206A, inductors, etc. The DC electricalcomponents include, among other things, capacitors 204B, an inductor206B, resistors, etc.

A heat sink assembly 150′ is in heat transfer relationship with the ACand DC electrical components 202A, 202B of the charger electronics 34.In the illustrated embodiment, the heat sink assembly 150′ is mountedonto and in contact with the PCB 140′. Heat transfers from theheat-generating electrical components 202A, 202B on the PCB 140′ to theheat sink 150′ through conduction. The heat sink 150′ is configured tobe disposed in the housing 18 proximate the rear 54, similar to the heatsink 150.

The illustrated heat sink assembly 150, 150′ includes a number (e.g.,three shown) of portions 208A, 208B, 208C extending across a width ofthe PCB 140, 140′, respectively. The first and second portions 208A,208B are formed of the heat-conducting material, such as, for example,aluminum, which is also electrically conductive. The first portion 208Aof the heat sink 150′ may be defined as the AC heat sink, and the secondportion 208B of the heat sink 150′ may be defined as the DC heat sink.The third portion 208C is formed of non-electrically-conductingmaterial, such as, for example, plastic, and is positioned between andelectrically insulates the AC and DC heat sink portions 208A, 208B. Theheat sink portions 208A, 208B, 208C are configured such that the airflow is directed through each of the portions 208A, 208B, 208C asdescribed above with respect to the heat sink 150. Furthermore, in theillustrated embodiment, the third portion 208C includes the slot (notshown) proximate the transformer 144 for directing a portion of the airflowing through the heat sink 150′ over the transformer 144.

With particular reference to FIG. 7, the light source (e.g., the LED;not shown) for each light pipe 190 is positioned on the DC portion 200Bof the PCB 140 (e.g., proximate the DC heat sink 208B). The LEDs arepowered by DC power, and the light pipes 190 are constructed to directthe light to the respective indicators on the top portion 42A of thehousing 18. In the illustrated embodiment, the light pipes 190 arebendable or flexible such that the desired position of the respectiveindicators on the top portion 42A may be achieved.

With particular reference to FIGS. 11A-11B, the PCB 140′ includes anin-board trace 210 (FIG. 11A) extending from the DC portion 200B of thePCB 140′ proximate the third heat sink portion 208C along a rear edge212 of the PCB 140′ to proximate the AC heat sink 208A and the ACportion 200A. The illustrated in-board trace 212 extends betweenopposite ends 214A, 214B.

With reference to FIGS. 11A and 13, in the illustrated construction, aLED 216A is positioned on and electrically connected to the in-boardtrace 210. As such, the LED 216A is powered by DC power from the DCportion 200B of the PCB 140′ but is positioned on the AC portion 200A.In the illustrated construction, the position of the LED 216A isadjustable along the trace 210 so that the LED 216A may be appropriatelypositioned relative to the indicator defined by the opening 130A withinthe housing 18 (e.g., directly below the indicator above the AC portion200A of the PCB 140, 140′). In the illustrated embodiment, the LED 216Ais positioned intermediate the first and second ends 214A, 214B of thein-board trace 210. Specifically, the LED 216A is positioned at adistance A from the first end 214A. The distance is adjustable such thatthe position of the LED 216A on the AC portion 200A is adjustable asnecessary to be positioned relative to the indicator.

Another LED 216B is positioned proximate the DC heat sink 208B forproviding light to the indicator defined by the opening 130B. A lightdirecting member 220A, 220B extends between an associated LED 216A, 216Band an indicator lens 134A′, 134B′ positioned within each opening 130A,130B. Due to the positioning of the LED 216A, 216B, the light directingmembers 220A, 220B have a substantially linear shape in a verticaldirection from the PCB 140′.

An isolating member 228 is positioned between the LED 216A and the heatsink portion 208A. The isolating member 228 is formed of non-conductingmaterial, such as, for example, plastic, and is operable to isolate theLED 216A on the AC portion 200A from interference caused by proximity tothe AC components 202A and electrically-conductive components (e.g., theheat sink portion 208A).

With reference to FIGS. 12-13, the PCB 140′ includes a slot 224extending along a portion of the AC heat sink portion 208A and thein-board trace 212. The slot 224 is configured to receive the isolatingmember 228 (FIG. 13). Specifically, in the illustrated embodiment, theisolating member 228 extends from the bottom housing portion 42B throughthe slot 224. In other embodiments (not shown), the isolating member 228may extend from the top housing portion 42A. Still further, in otherembodiments (not shown), the isolating member 228 may be positioned onthe PCB 140′, and the PCB 140′ may not include the slot 224 to receivethe isolating member 228. In such a construction, isolating material maybe provided on the PCB 140′ on which the isolating member 228 may bemounted.

The illustrated isolating member 228 has a generally box-like shape andis positioned between the LED 216A and the AC heat sink portion 208A. Alateral direction B of the charger 10 extends through opposite sides ofthe isolating member 228 (e.g., its thickness). In some embodiments, thethickness may be about 1 millimeter (mm) or more. Still further, in someembodiments, the thickness may be between about 1 mm and about 2.2 mm.In the illustrated embodiment, the thickness is about 1.6 mm.

The isolating member 228 is positioned at a distance E from the AC heatsink portion 208A (e.g., about 2.6 mm in the illustrated construction).In addition, the LED 216A is spaced from the isolating member 228 by adistance F along the lateral direction B (e.g., about 7.4 mm in theillustrated construction). Rather than being linear, in otherconstructions (not shown), the isolating member 228 may curve around theLED 216A with a radius of curvature being equal to or greater than thedistance F.

In the illustrated construction, a total distance G that the LED 216A isspaced from the AC heat sink portion 208A is about 10 mm. In otherembodiments, the total distance G is at least about 8 mm, the minimumover-surface distance (creepage) between the LED 216A and the AC heatsink portion 208A. Still further in other embodiments, the totaldistance G is between about 10 mm and about 12 mm.

The opposite ends of the isolating member 228 are spaced from the LED216A by a distance H (e.g., about 18.6 mm or more). In some embodiments,the distance H is about 18.664 mm or more. Furthermore, in someembodiments, the distance is between about 18.664 mm and about 22.8664mm. In the illustrated embodiment, the distance H is about 18.8664 mm.In the illustrated construction, the LED 216A is positioned equidistantbetween the ends of the isolating member 228. Furthermore, in otherembodiments, the distance H is about 8 mm or more.

The isolating member 228 may be sized to facilitate adjustment of theLED 216A on the trace 212. The size of the isolating member 228 may besufficient to maintain a minimum distance (e.g., about 18.8664 mm)between the LED 216A and the proximate edge of the isolating member 228in the various adjusted positions of the LED 216A along the trace 212.In other constructions, the isolating member 228 may also be adjusted toa position corresponding to the position of the LED 216A.

The top of the isolating member 228 is spaced above the LED 216A by adistance I which may be the same as or different than the distance H. Insome embodiments, the distance I is about 14.8 mm or more (e.g., 14.8677mm in the illustrated construction). In some embodiments, the distanceis between about 14.8677 mm and about 18.8677 mm. Furthermore, in otherembodiments, the distance I is about 8 mm or more.

In other constructions (not shown), the isolating member 228 may have adifferent shape. For example, the isolating member 228 may be curved.With the curved isolating member 228, a horizontal distance from the LED216A to the lateral edge of the isolating member 228 may be at least theminimum distance (e.g., 8 mm to each side), a vertical distance from theLED 216A to the top of the isolating member 228 may be at least theminimum (e.g., about 8 mm), and the wall of the isolating member 228 maybe curved therebetween. In still other constructions (not shown),portions of the isolating member 228 beyond the minimum distances may beremoved (e.g., the corner portions removed to approximate the curvedisolating member 228).

Thus, the utility model may provide, among other things, a charger 10with a LED 216A supported on an AC side of a PCB 140′ and isolated fromelectrical interference by AC components on the PCB 140′. The charger 10may include a LED that is adjustably positioned on the AC side of thePCB 140′.

Although the utility model has been described in detail with referenceto certain preferred embodiments, variations and modifications existwithin the scope and spirit of one or more independent aspects of theutility model as described.

One or more independent features and/or independent advantages of theutility model may be set forth in the claims.

1. A battery charger comprising: a housing including a support portionoperable to support a battery for charging; charging circuitry operableto supply current to charge the battery; a printed circuit board (PCB)supported by the housing, the PCB having a first portion supportingalternating current (AC) electrical components and a second portionsupporting direct current (DC) electrical components; an indicatorsupported on the housing and associated with the support portion, theindicator including a light-emitting diode (LED) supported on the firstportion of the PCB and operable to emit light; and an isolating memberpositioned between the AC electrical components and the LED. 2.(canceled)
 3. (canceled)
 4. (canceled)
 5. (canceled)
 6. (canceled) 7.(canceled)
 8. (canceled)
 9. The charger of claim 1, wherein the ACelectrical components include a capacitor and a resistor, and whereinthe DC electrical components include a capacitor and an inductor. 10.(canceled)
 11. The charger of claim 1, wherein the isolating member isformed of electrically-insulating material.
 12. (canceled) 13.(canceled)
 14. (canceled)
 15. (canceled)
 16. (canceled)
 17. (canceled)18. (canceled)
 19. (canceled)
 20. (canceled)
 21. (canceled) 22.(canceled)
 23. (canceled)
 24. (canceled)
 25. The charger of claim 26,wherein a heat sink is supported on the first portion of the PCB, theheat sink being formed of electrically-conductive material to form theelectrically-conductive component.
 26. The charger of claim 1, whereinthe LED is positioned no less than about 8 mm from anelectrically-conductive component on the first portion of the PCB. 27.The charger of claim 26, wherein the LED is positioned up to about 12 mmfrom the electrically-conductive component.
 28. The charger of claim 27,wherein the LED is positioned about 10 mm from theelectrically-conductive component.
 29. The charger of claim 1, wherein atrace on the PCB is electrically connected to the second portion of thePCB, the trace extending from the second portion and along the firstportion, the LED being electrically connected to and receiving DC powerthrough the trace, wherein the LED is selectively positioned along alength of the trace.
 30. (canceled)
 31. The charger of claim 1, whereinthe PCB defines a slot, and wherein the housing includes a rib receivedthrough the slot and providing the isolating member positioned betweenthe AC electrical components and the LED.
 32. The charger of claim 1,wherein the isolating member is positioned on the PCB between the ACelectrical components and the LED.
 33. A battery charger comprising: ahousing including a support portion operable to support a battery packfor charging; charging circuitry operable to supply current to chargethe battery pack; a printed circuit board (PCB) supported by thehousing, the PCB having a first portion supporting alternating current(AC) components and a second portion supporting direct current (DC)components, a trace on the PCB being electrically connected to thesecond portion of the PCB, the trace extending from the second portionand along the first portion; and an indicator supported on the housingand associated with the support portion, the indicator including alight-emitting diode (LED) supported on the first portion of the PCB andoperable to emit light, the LED being electrically connected to andreceiving DC power through the trace, the LED being selectivelypositioned along a length of the trace.
 34. The charger of claim 33,further comprising an isolating member positioned between the ACelectrical components and the LED, and wherein the isolating member isformed of electrically-insulating material.
 35. (canceled) 36.(canceled)
 37. (canceled)
 38. (canceled)
 39. (canceled)
 40. (canceled)41. (canceled)
 42. (canceled)
 43. (canceled)
 44. (canceled) 45.(canceled)
 46. (canceled)
 47. (canceled)
 48. (canceled)
 49. (canceled)50. (canceled)
 51. The charger of claim 34, wherein the isolating memberis positioned on the PCB between the AC electrical components and theLED.
 52. The charger of claim 33, wherein the housing includes a firstsupport portion operable to support a first battery for charging and asecond support portion operable to support a second battery forcharging.
 53. The charger of claim 52, wherein the first support portionis positioned above the first portion of the PCB, and wherein the secondsupport portion is positioned above the second portion of the PCB. 54.(canceled)
 55. The charger of claim 52, wherein the indicator is a firstindicator associated with the first support portion, and wherein thecharger further includes a second indicator associated with the secondsupport portion.
 56. The charger of claim 33, wherein the housingdefines an opening through which light from the LED is visible, andwherein the LED is positioned substantially vertically below theopening.
 57. (canceled)
 58. (canceled)
 59. (canceled)
 60. (canceled) 61.The charger of claim 34, wherein the LED is positioned no less thanabout 8 mm from an electrically-conductive component on the firstportion of the PCB.
 62. The charger of claim 61, wherein the LED ispositioned about 10 mm from the electrically-conductive component.
 63. Abattery charger comprising: a housing including a support portionoperable to support a battery for charging; charging circuitry operableto supply current to charge the battery; a printed circuit board (PCB)supported by the housing, the PCB having a first portion supportingalternating current (AC) electrical components and a second portionsupporting direct current (DC) electrical components; and an indicatorsupported on the housing and associated with the support portion, theindicator including a light-emitting diode (LED) supported on the firstportion of the PCB and operable to emit light, the LED being positionedmore than 8 mm from the AC electrical components.
 64. The charger ofclaim 63, wherein the LED is positioned about 10 mm from the ACelectrical components.
 65. The charger of claim 63, further comprisingan isolating member positioned between the AC electrical components andthe LED, and wherein the isolating member is formed ofelectrically-insulating material.
 66. (canceled)
 67. (canceled) 68.(canceled)
 69. (canceled)
 70. (canceled)
 71. (canceled)
 72. (canceled)73. (canceled)
 74. (canceled)
 75. (canceled)
 76. (canceled) 77.(canceled)
 78. (canceled)
 79. (canceled)
 80. (canceled)
 81. (canceled)82. The charger of claim 65, wherein the isolating member is positionedon the PCB between the AC electrical components and the LED. 83.(canceled)
 84. (canceled)
 85. (canceled)
 86. (canceled)
 87. (canceled)88. (canceled)
 89. (canceled)
 90. (canceled)
 91. (canceled)
 92. Thecharger of claim 63, wherein a trace on the PCB is electricallyconnected to the second portion of the PCB, the trace extending from thesecond portion and along the first portion, the LED being electricallyconnected to and receiving DC power through the trace, and wherein theLED is selectively positioned along a length of the trace. 93.(canceled)